Radiator fan assembly structure and method of forming

ABSTRACT

A radiator fan assembly structure has a base board with a seating surface and a stator installing surface; a stator inserting and positioning part, configured in the center of the stator installing surface of the base board; a stator set, has a silicon-steel plate, a coil and an insulate frame; and a plastic assembly seat formed integrally on the stator set, which is formed through a projection from the center of the insulate frame of the stator set. The shape of the plastic assembly seat enables it to be inserted into the stator inserting and positioning part. An axis is combined with the plastic assembly seat, with its root part fixed on the center of the plastic assembly seat. A rotor blade assembly has a wheel hub, blades, a bush, a bearing assembly and a magnet ring. The radiator fan runs smoothly and quietly.

CROSS-REFERENCE TO RELATED U.S. APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT Not applicable. REFERENCETO AN APPENDIX SUBMITTED ON COMPACT DISC Not applicable. BACKGROUND OFTHE INVENTION

1. Field of the Invention

The present invention relates generally to a radiator fan, and moreparticularly to an innovative assembly structure of the rotor and statorof the radiator fan and its forming method.

2. Description of Related Art Including Information Disclosed Under 37CFR 1.97 and 37 CFR 1.98.

In a prior-art radiator fan with its axis configured on the side of therotor wheel hub, there are many places with mismatch errors, forexample, mismatch between the axis and the rotor wheel hub, mismatchbetween the rotor magnet ring and the stator coil, mismatch between theaxis and the stator bearing, and mismatch between the stator bearing andthe axle seat. There are always problems and shortcomings of excessivenoise in actual manufacturing of such radiator fans due to thedifficulty in accurate positioning.

To overcome this problem, the industry has developed a new kind ofradiator fan with reversed axis positioning. In the structuralconfiguration of such a radiator fan, as the root part of the rotor axisis inversely combined to the stator seat, vertical accuracy between theaxis and the stator seat can be easily realized. However, because thecoil assembly of the stator is attached to the projecting barrelpreformed in the stator seat as a singular module, after the assembly,there may be an excessive mismatch error between the coil assembly andthe axis, and as a result, after assembly of the rotor and stator, it ishard to realize accurate positioning between the coil of the stator andthe magnet ring of the rotor, and the problem of unsmooth and noisyrunning will still exist.

Thus, to overcome the aforementioned problems of the prior art, it wouldbe an advancement if the art to provide an improved structure that cansignificantly improve the efficacy.

Therefore, the inventor has provided the present invention ofpracticability after deliberate design and evaluation based on years ofexperience in the production, development and design of relatedproducts.

BRIEF SUMMARY OF THE INVENTION

The main feature of the innovative “radiator fan assembly structure andits forming method” disclosed in the present invention is that the axisof the radiator fan is integrated onto the plastic construction of thestator set, and the stator set can be fitted into the base board, sothat the axis, the silicon-steel plate of the stator set, and the coilassembly can be accurately aligned through planning and designing of theprojection mould. In this way, when the rotor blade assembly, the statorset, and the axis are assembled, the mismatch error between these threecomponents can be minimized, and the assembly error between the statorset and the base board will not affect the accurate alignment betweenthe stator set, the axis, and the rotor blade assembly. In this way, theassembly accuracy of the radiator fan can be dramatically improved, therunning will be smoother, and noise will be effectively reduced. Theseconstitute the advantages and practical advancement of the presentinvention.

Although the invention has been explained in relation to its preferredembodiment, it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention as hereinafter claimed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded sectional view of a preferred embodiment of thepresent invention.

FIG. 2 is an assembled sectional view of a preferred embodiment of thepresent invention.

FIG. 3 depicts an example implementation with the plastic assembly seatconfigured with a positioning column.

FIG. 4 depicts an example implementation as shown in FIG. 3 with the endof the positioning column formed with a hot melt expanded tip.

FIG. 5 depicts an example implementation with the stator set insulateframe formed with a positioning projector column.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 shows a preferred embodiment of the radiator fan assemblystructure and its forming method disclosed in the present invention.However, such an embodiment is presented for illustrative purpose only,and it is noted that the invention is not limited to the specificembodiment described herein.

Said radiator fan assembly structure comprises the following components.

A base board 10, which can be a metal board, comprises a seating surface11 and a stator installing surface 12. The stator installing surface 12is configured with a circuit board 13.

A stator inserting and positioning part 14 is configured in center ofthe stator installing surface 12 of the base board 10.

A stator set 20 which comprises a multiple silicon-steel plate 21, acoil 22 and an insulate frame 23. The insulate frame 23 is to cover andset the silicon-steel plate 21.

A plastic assembly seat 30 is formed integrally on the stator set 20.The plastic assembly seat 30 is formed through a projection from thecenter of the insulate frame 23 of the stator set 20. The shape of theplastic assembly seat 30 enables it to be inserted into the statorinserting and positioning part 14 configured in the center of statorinstalling surface 12 of the base board 10.

An axis 40 is combined with the plastic assembly seat 30. The root part41 of the axis 40 is vertically fixed on the center of the plasticassembly seat 30.

A rotor blade assembly 50 which comprises a wheel hub 51, multipleblades 52, a bush 53, a bearing assembly 54 and a magnet ring 55. Theblades 52 are configured at intervals outside the peripheral wall of thewheel hub 51. The bush 53 is configured in the internal center of thewheel hub 51. The bearing assembly 54 is configured inside the bush 53to fit the axis 40. The magnet ring 55 is configured around the innerperipheral wall of the wheel hub 51.

The stator inserting and positioning part 14 can be implemented in theshape of a through hole (as depicted in FIGS. 1 and 2) or an insiderecessing groove, so that the plastic assembly seat 30 can be tightlyinserted into the stator inserting and positioning part 14 (as depictedin FIG. 2).

As depicted in FIGS. 3 and 4, the plastic assembly seat 30 can alsointegrally form a positioning column 31 projecting to the direction ofthe base board 10, and a through hole 16 is configured on thecorresponding position of the base board 10 for the positioning column31 to go through. Moreover, a hot-melt expanded tip 32 is formed throughheat pressing (as marked by Arrow L1 in FIG. 4) at the end of thepositioning column 31 to resist against the seating surface 11 of thebase board 10.

As depicted in FIG. 5, the insulate frame 23 of the stator set 20 can bemade of plastic material, and the insulate frame 23 integrally forms apositioning projector column 24 projecting to the direction of the baseboard 10, and a through hole 15 is configured on the correspondingposition of the base board 10 for the positioning projector column 24 togo through. Moreover, a hot-melt expanded tip 25 is formed at the end ofthe positioning projector column 24 to resist against the seatingsurface 11 of the base board 10.

In reference to the structure set forth above, the forming method of theradiator fan structure disclosed in the present invention is describedas follow:

Said radiator fan mainly comprises a base board 10, a stator set 20, anaxis 40, and a rotor blade assembly 50; wherein the base board 10comprises a seating surface 11 and a stator installing surface 12, withthe stator installing surface 12 configured with a circuit board 13. Thestator set 20 comprises multiple silicon-steel plates 21, a coil 22 andan insulate frame 23, with the insulate frame 23 configured to cover andset the silicon-steel plate 21. The rotor blade assembly 50 comprises awheel hub 51, multiple blades 52, a bush 53, a bearing assembly 54 and amagnet ring 55. Said blades 52 are configured at intervals outside theperipheral wall of the wheel hub 51. The bush 53 is configured in theinternal center of the wheel hub 51. The bearing assembly 54 isconfigured inside the bush 53 to fit the axis 40. The magnet ring 55 isconfigured around the inner peripheral wall of the wheel hub 51.

Said forming method has the following features:

A stator inserting and positioning part 14 is configured in the centerof the stator installing surface 12 of the base board 10.

When manufacturing the stator set 20, the silicon-steel plate 21 and theaxis 40 are fixed at the same time in a projection forming mould bymeans of intramodal projection forming, and then the insulate frame 23and plastic assembly seat 30 are formed through projection molding. Inthis way, the axis 40 is accurately fixed and integrated in the rightcenter of the stator set 20.

As the plastic assembly seat 30 and stator inserting and positioningpart 14 are configured for insertion, the stator set 20 can be fixed onthe base board 10.

As the bearing assembly 54 can allow the axis 40 to insert into, therotor blade assembly 50 can be joined with the stator set 20, and untilnow, the whole radiator fan is completely assembled.

In the above forming method, the plastic assembly seat 30 and the statorinserting and positioning part 14 are joined and fixed through tightfitting between the projector part and the groove (as depicted in FIGS.1 and 2).

In the above forming method, the tight fixing between the plasticassembly seat 30 and the base board 10, or between the insulate frame 23of the stator set 20 and the base board 10 are realized by letting theprojector positioning column 31 to go through the base board 10, and byforming an expanded tip 32 at the end of the positioning column 31through hot melting (the style depicted in FIGS. 3 and 4, or the styledepicted in FIG. 5).

In the above forming method, the insulate frame 23 of the stator set 20,the plastic assembly seat 30 and the axis 40 are formed integrally as awhole through projection forming.

1. A radiator fan assembly structure comprising: a base board,comprising a seating surface and a stator installing surface; the statorinstalling surface is configured with a circuit board; a statorinserting and positioning part, configured in the center of the statorinstalling surface of the base board; a stator set, comprising asilicon-steel plate, a coil and an insulate frame; a plastic assemblyseat formed integrally on the stator set; the plastic assembly seat isformed through a projection from the center of the insulate frame of thestator set; the shape of the plastic assembly seat enables it to beinserted into the stator inserting and positioning surface of the baseboard; an axis combined with the plastic assembly seat; the root part ofthe axis is vertically fixed on the center of the plastic assembly seat;and a rotor blade assembly, which comprises a wheel hub, multipleblades, a bush, a bearing assembly and a magnet ring; the blades areconfigured at intervals outside the peripheral wall of the wheel hub;the bush is configured in the internal center of the wheel hub; thebearing assembly is configured inside the bush to fit the axis; themagnet ring is configured around the inner peripheral wall of the wheelhub.
 2. The structure defined in claim 1, wherein the stator insertingand positioning part of the base board is implemented in the shape of athrough hole or an inside recessing groove, so that the plastic assemblyseat can be tightly inserted into the stator inserting and positioningpart.
 3. The structure defined in claim 1, wherein the plastic assemblyseat integrally forms a positioning column projecting to the directionof the base board, and a through hole is configured on the correspondingposition of the base board for the positioning column to go through; ahot-melt expanded tip is formed at the end of the positioning column toresist against the seating surface of the base board.
 4. The structuredefined in claim 1, wherein the insulate frame of the stator set is madeof plastic material, and the insulate frame integrally forms apositioning projector column projecting to the direction of the baseboard, and a through hole is configured on the corresponding position ofthe base board for the positioning projector column to go through; ahot-melt expanded tip is formed at the end of the positioning projectorcolumn to resist against the seating surface of the base board.
 5. Aradiator fan assembly structure forming method, wherein said radiatorfan mainly comprises a base board, a stator set, an axis, and a rotorblade assembly; wherein the base board comprises a seating surface and astator installing surface, with the stator installing surface configuredwith a circuit board; the stator set comprises a silicon-steel plate, acoil and an insulate frame; the insulate frame covers and sets thesilicon-steel plate; the rotor blade assembly comprises a wheel hub,multiple blades, a bush, a bearing assembly and a magnet ring; saidblades are configured at intervals outside the peripheral wall of thewheel hub; the bush is configured in the internal center of the wheelhub; the bearing assembly is configured inside the bush to fix the axis;the magnet ring is configured around the inner peripheral wall of thewheel hub; said forming method has the following features: a statorinserting and positioning part is configured in the center of the statorinstalling surface of the base board; when manufacturing the stator set,the silicon-steel plate and the axis are fixed at the same time in aprojection forming mould by means of intramodal projection forming, andthen the insulate frame and plastic assembly seat are formed throughprojection molding; in this way, the axis is accurately fixed andintegrated in the right center of the stator set; as the plasticassembly seat and stator inserting and positioning part are configuredfor insertion, the stator set can be fixed on the base board; as thebearing assembly can allow the axis to insert into, the rotor bladeassembly can be joined with the stator set.
 6. The method defined inclaim 5, wherein the plastic assembly seat and stator inserting andpositioning part are joined and fixed through tight fitting between theprojector part and the groove.
 7. The method defined in claim 5, whereinthe tight fixing between the plastic assembly seat and the base board,or between the insulate frame of the stator set and the base board arerealized by letting the projector positioning column to go through thebase board, and by forming an expanded tip at the end of the positioningcolumn through hot melting.
 8. The method defined in claim 5, whereinthe insulate frame of the stator set, the plastic assembly seat and theaxis are formed integrally as a whole through projection forming.